A method for improving the clamping efficiency of multi-process die-casting molds for automobiles

Abstract

This invention discloses a method for improving the clamping efficiency of multi-process die-casting molds for automobiles. The method analyzes the clamping requirements of multiple processes, including liquid injection molding, cooling and solidification, demolding, and cleaning preparation, to determine the process requirements of each process. It pre-treats the surface of the die-casting mold substrate, machining a multi-process compatible positioning structure to form a highly adaptable treated surface. A multi-process integrated clamping scheme is designed, employing modular assembly to form a highly efficient clamping functional structure. Positioning elements are optimized in an automated process environment to achieve rapid switching between processes, significantly improving clamping efficiency. This invention optimizes the multi-process clamping process through modular design and dynamic adjustment mechanisms, ensuring efficient and stable production, and is applicable to the manufacturing of automotive die-casting molds.

Description

Technical Field

[0001] This invention relates to the field of automobile manufacturing, specifically to a method for improving the clamping efficiency of multi-process die-casting molds for automobiles. It is applicable to the clamping optimization of multiple processes such as liquid injection molding, cooling and solidification, demolding and removal, and cleaning and preparation. The aim is to improve clamping efficiency and production stability through modular design and automated processes. Background Technology

[0002] In the automotive manufacturing industry, die-casting molds are widely used in the production of high-precision, high-strength automotive parts, such as engine blocks and body structural components. Traditional die-casting mold clamping methods are typically designed for a single process and are ill-suited to the complex requirements of multiple processes, including liquid injection molding, cooling and solidification, demolding, and cleaning. This results in long process changeover times, insufficient clamping stability, and low production efficiency. Existing technologies often rely on fixed fixtures and lack modular design, making rapid process changeover difficult. Furthermore, surface treatment processes cannot meet the compatibility requirements of multiple processes, easily leading to positioning deviations and mold wear. In addition, traditional methods lack automated optimization tools, and clamping adjustments are time-consuming, making it difficult to adapt to the efficient and continuous pace of automotive die-casting production, thus limiting overall production efficiency and mold lifespan. Summary of the Invention

[0003] The purpose of this invention is to provide a method for improving the efficiency of multi-process clamping of automotive die-casting molds. Addressing the problems of long switching times, insufficient stability, and low production efficiency in traditional clamping methods involving multiple processes such as liquid injection molding, cooling and solidification, demolding, and cleaning preparation, this invention achieves rapid switching between processes and improves clamping efficiency and production stability by analyzing multi-process clamping requirements, machining multi-process compatible positioning structures, designing modular clamping schemes, and optimizing positioning elements through automation. Simultaneously, highly adaptable surface treatment reduces positioning deviations and mold wear, extending service life and meeting the demands of efficient and continuous automotive die-casting production.

[0004] Specifically, the method includes the following steps: analyzing the multi-process processing requirements of automotive die-casting molds, identifying the clamping requirements of the injection molding, cooling and solidification, demolding and removal, and cleaning preparation processes; performing surface pretreatment on the die-casting mold substrate, processing a multi-process compatible positioning structure to form a highly adaptable treated surface; designing a multi-process integrated clamping scheme, forming an efficient clamping functional structure through modular assembly; and performing automated multi-process optimization of the clamping functional structure in an automated process environment, enabling the positioning elements to quickly switch between processes, thereby obtaining an automotive die-casting mold with improved clamping efficiency.

[0005] Furthermore, the steps for analyzing the multi-process machining requirements of automotive die-casting molds include: for the liquid injection molding process, determining the clamping force requirement range to be 2500-4500N to meet the high pressure requirements of aluminum alloy die casting; for the cooling solidification and demolding processes, setting the process changeover time to less than 8 seconds to meet the high-efficiency production rhythm; for the cleaning and preparation process, determining the positioning accuracy requirement to be less than 0.015mm to ensure the machining quality of complex molds; based on the above requirements, setting the multi-process clamping efficiency improvement target to reduce the total changeover time by 35-55%.

[0006] Furthermore, the steps of surface pretreatment of the die-casting mold substrate and processing the multi-process compatible positioning structure include: selecting high-strength mold steel or high-hardness aluminum alloy as the die-casting mold substrate; forming a multi-slot positioning structure by precision CNC machining, with a slot depth of 0.5-2.0mm and a slot width of 2.0-6.0mm to balance strength and processing efficiency; and after high-pressure cleaning and rust prevention treatment, drying at 80-100℃ for 20-45 minutes to form the highly adaptable treated surface.

[0007] Furthermore, the multi-slot positioning structure includes a deep slot for the liquid injection process and a shallow slot for the demolding process. The depth of the deep slot is 1.0-2.0 mm, and the depth of the shallow slot is 0.5-1.0 mm, supporting rapid switching between processes.

[0008] Furthermore, the steps of designing the multi-process integrated clamping scheme and forming an efficient clamping functional structure through modular assembly include: designing a first clamping module, configuring high-precision positioning and dynamic locking functions, with a locking force of 1200-2800N to meet the stability requirements of multiple processes; fixing the first clamping module to the processing surface through a quick connection method to form a first clamping layer; designing a second clamping module, integrating a dynamic adjustment mechanism, and assembling it on the first clamping layer to form the efficient clamping functional structure.

[0009] Furthermore, the step of automating multi-process optimization of the clamping functional structure to enable rapid switching between processes for the positioning element includes: placing the clamping functional structure in an automated process environment that supports multi-process clamping optimization, with an environment accuracy of 0.01-0.03mm and a switching speed of 20-40mm / s to meet the requirements of high-precision mold processing; simulating multi-process switching through an automated program, adjusting the positioning element for 30-80 minutes to ensure that the switching error is less than 0.02mm; and curing and locking at room temperature for 1.5-3 hours to obtain the automotive die-casting mold with improved clamping efficiency.

[0010] Furthermore, the step of automating and optimizing the clamping functional structure further includes applying a high-temperature resistant and corrosion-resistant coating to the surface of the clamping functional structure, with a coating thickness of 10-30 μm, to improve durability under high temperature and high pressure environments.

[0011] Furthermore, the steps following the application of the high-temperature resistant and anti-corrosion coating also include: conducting a multi-process clamping efficiency test, covering four processes: liquid injection, cooling, demolding, and cleaning, with a test time of 15-60 minutes, to verify the achievement of the clamping efficiency improvement target; when the clamping changeover time is reduced by more than 45%, the automotive die-casting mold is quality certified.

[0012] Furthermore, the thickness of the first clamping layer is 15-50mm, and the thickness of the second clamping layer is 8-30mm. The thickness of the first clamping layer is greater than that of the second clamping layer to ensure the stability of multi-process clamping.

[0013] Furthermore, the multi-process integrated clamping solution achieves seamless connection between liquid injection, cooling, demolding, and cleaning processes through a dynamic adjustment mechanism, and the clamping efficiency improvement parameter satisfies the following formula: Where E represents the clamping efficiency improvement parameter, represents the clamping force weighting coefficient, represents the changeover time weighting coefficient, γ represents the positioning accuracy weighting coefficient, represents the clamping force distribution, represents the process changeover time, and Pc represents the positioning accuracy. β and γ are determined by the process requirements and the properties of the mold material.

[0014] This invention significantly improves the clamping efficiency of automotive die-casting molds by analyzing multi-process clamping requirements, machining multi-process compatible positioning structures, designing modular clamping schemes, and optimizing positioning elements through automation. It enables rapid switching between injection molding, cooling and solidification, demolding, and cleaning preparation processes, shortening process changeover time and increasing production efficiency. Highly adaptable surface treatment enhances mold wear resistance and positioning accuracy, reduces positioning deviations, and extends mold lifespan. The modular clamping structure and dynamic adjustment mechanism ensure clamping stability, meeting the needs of complex processes. Automated process environment optimization reduces manual intervention time, improves continuous production capacity, and adapts to the efficient production rhythm of automotive die-casting. Attached Figure Description

[0015] Figure 1 Flowchart of the method for improving the multi-process clamping efficiency of automotive die-casting molds provided by the present invention;

[0016] Figure 2 Flowchart of the method for machining a multi-process compatible positioning structure for automotive die-casting molds provided by the present invention; Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0018] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature; in the description of this application, unless otherwise stated, "multiple" means two or more.

[0019] To more clearly illustrate the technical solution of the present invention, the present invention will be described in detail below with reference to specific embodiments, but it should not be construed as a limitation on the scope of protection of the present invention.

[0020] This embodiment provides a method for improving the multi-process clamping efficiency of automotive die-casting molds, such as... Figure 1 As shown, this is a die-casting process suitable for producing high-precision parts such as automobile engine cylinder blocks.

[0021] Step S01: Analyze the multi-process processing requirements of automotive die-casting molds and identify the clamping requirements for the liquid injection molding, cooling and solidification, demolding and removal and cleaning preparation processes.

[0022] Specifically, in automotive die casting production, the process characteristics of the injection molding, cooling and solidification, demolding, and cleaning preparation steps are first analyzed in detail. For the injection molding step, the clamping system must withstand the impact of high-pressure molten aluminum alloy while maintaining the mold's seal. The cooling and solidification step requires the clamping system to maintain mold stability to prevent deformation. The demolding step requires rapid mold release to reduce process changeover time, while the cleaning preparation step ensures the mold surface is clean and accurately positioned. Furthermore, through process simulation and production data analysis, the clamping force, positioning accuracy, and changeover time requirements for each step are identified, forming a process requirement list to provide a basis for subsequent design. Understandably, this step, through systematic analysis, ensures that the clamping scheme meets the differentiated needs of multiple processes, improving overall production efficiency.

[0023] Step S02: Perform surface pretreatment on the die-casting mold substrate, process a multi-process compatible positioning structure, and form a highly adaptable treated surface.

[0024] Specifically, high-strength mold steel is selected as the base material for the die-casting mold, and a multi-slot positioning structure is machined using precision CNC milling equipment. During the machining process, high-speed milling technology is used to form positioning slots with a depth of 0.5-2.0 mm and a width of 2.0-6.0 mm. The slot types include deep slots for the liquid injection process and shallow slots for the demolding process, arranged alternately to support rapid switching. Further, after machining, high-pressure water cleaning is used to remove surface residues, and a rust inhibitor is sprayed on. Subsequently, it is dried in a drying oven at 80-100℃ for 20-45 minutes to form a highly adaptable surface that is wear-resistant and corrosion-resistant. Understandably, this surface not only enhances the durability of the mold but also provides a foundation for the precise positioning of subsequent clamping modules.

[0025] Step S03: Design a multi-process integrated clamping solution, and form an efficient clamping functional structure through modular assembly.

[0026] Specifically, based on the requirements of multiple processes, an integrated clamping solution including a first clamping module and a second clamping module is designed. The first clamping module is equipped with high-precision positioning and is fixed to a highly adaptable processing surface via a quick connection to form the first clamping layer. The locking force is controlled between 1200-2800N to meet stability requirements. The second clamping module integrates a dynamic adjustment mechanism and is assembled on the first clamping layer, enabling process switching through adjustable positioning elements. Furthermore, the modular design adopts standardized interfaces to ensure rapid assembly and disassembly of modules, adapting to the differentiated requirements of liquid injection, cooling, demolding, and cleaning processes. Understandably, this design improves the flexibility and compatibility of the clamping system and reduces process changeover time.

[0027] Step S04: Optimize the clamping functional structure through automated multi-process in an automated process environment, so that the positioning element can switch quickly between processes, and obtain an automotive die-casting mold with improved clamping efficiency.

[0028] Specifically, the clamping structure is placed in an automated process environment supporting multi-process optimization, with environmental accuracy controlled within 0.01-0.03 mm and a switching speed of 20-40 mm / s. An automated program simulates the switching process of injection, cooling, demolding, and cleaning. By adjusting the angle and position of the positioning elements, the switching path is optimized, with an adjustment time of 30-80 minutes, ensuring a switching error of less than 0.02 mm. Further, after adjustment, the structure is cured and locked at room temperature for 1.5-3 hours to fix the optimized positioning structure. Understandably, this step, through automation optimization, significantly shortens process changeover time and improves clamping efficiency, making it suitable for high-efficiency automotive die-casting production.

[0029] This invention analyzes the clamping requirements of multiple processes, including liquid injection molding, cooling and solidification, demolding and cleaning, and optimizes the clamping scheme design, significantly shortening process changeover time and improving production efficiency. By pre-treating the mold substrate and machining a multi-process compatible positioning structure, a highly adaptable surface is formed, enhancing mold wear resistance and positioning accuracy, reducing positioning deviations, and extending mold lifespan. A modular, multi-process integrated clamping scheme is adopted to form a highly efficient clamping functional structure, coupled with a dynamic adjustment mechanism, ensuring rapid switching and clamping stability between processes. Optimizing positioning elements in an automated process environment further improves switching accuracy and efficiency, reduces manual intervention time, meets the high-efficiency and continuous requirements of automotive die casting production, and significantly improves overall production efficiency and mold reliability.

[0030] In some embodiments, an implementation method for multi-process machining requirement analysis in a method for improving the clamping efficiency of multi-process die-casting molds for automobiles is provided, which is applicable to the die-casting process for producing high-precision parts such as automobile gearbox housings.

[0031] Specifically, for the liquid injection molding process, the clamping force requirement range is determined to be 2500-4500N to meet the high pressure requirements of aluminum alloy die casting.

[0032] In the liquid injection molding process, the impact force of molten metal on the mold during aluminum alloy die casting is analyzed. Considering the geometric characteristics of complex components such as the gearbox housing, process simulation determines that the clamping system needs to provide a clamping force of 2500-4500N to ensure the mold maintains its sealing and stability under high-pressure liquid injection (typically using an 800-2000 ton die casting machine). Furthermore, finite element analysis is used to simulate the force distribution on the mold, verifying whether the clamping force meets the process requirements and preventing mold displacement or deformation. Understandably, this step, through precise clamping force range setting, provides reliable clamping support for the liquid injection process, improving production quality.

[0033] Furthermore, for the cooling, curing, and demolding processes, the process switching time is set to be less than 8 seconds to meet the requirements of efficient production.

[0034] Specifically, for the cooling and solidification process, the thermal stress changes of the mold during cooling are analyzed to ensure the stability of the clamping system during the cooling phase. Simultaneously, a rapid release mechanism is designed for the demolding and removal process. By optimizing the release path of the clamping structure, the process changeover time is set to less than 8 seconds to adapt to the rhythm of a high-efficiency production line. Furthermore, through time and motion analysis, the switching process between cooling and demolding is simulated, and the sequence of clamping, release, and repositioning actions is adjusted to reduce unnecessary waiting time. Specifically, the rapid release mechanism uses a pneumatic quick-release clamping device, controlling the clamping and release actions through a preset air pressure (0.4-0.6 MPa). Combined with an optimized sliding guide rail design (guide rail friction coefficient less than 0.1), the changeover time is shortened to 6-8 seconds, ensuring a high-efficiency production rhythm. Understandably, this step significantly improves multi-process production efficiency by shortening the changeover time.

[0035] Furthermore, for the cleaning and preparation process, the positioning accuracy requirement is set to be less than 0.015mm to ensure the processing quality of complex molds.

[0036] Specifically, in the cleaning and preparation process, the requirements for mold surface cleaning and repositioning are analyzed. For the precision requirements of complex molds such as gearbox housings, a positioning accuracy of less than 0.015mm is set to ensure that the mold can quickly return to a high-precision positioning state after cleaning. Furthermore, optical measurement technology is used to verify the positional deviation of the mold positioning points, and the positioning elements of the clamping system are adjusted to meet the accuracy requirements. In addition, a laser positioning system (resolution 0.005mm) is used for real-time monitoring, combined with closed-loop feedback control to adjust the fine-tuning mechanism of the positioning elements (step accuracy 0.01mm), ensuring that the positioning deviation is controlled within 0.015mm, meeting the processing quality requirements of high-precision molds. Understandably, this step ensures the quality of the cleaning process through high-precision positioning, laying the foundation for the subsequent liquid injection process.

[0037] Furthermore, based on the above requirements, the target for improving the efficiency of multi-process clamping is set as reducing the total changeover time by 35-55%.

[0038] Specifically, considering the clamping requirements of the injection molding, cooling and solidification, demolding, and cleaning preparation processes, multi-process clamping efficiency improvement targets are set. By optimizing the clamping structure and changeover process, the total changeover time is reduced by 35-55%. Actual production line testing is conducted, and the changeover time of each process is recorded. Data before and after optimization is compared to confirm the efficiency improvement effect, ensuring that the high-efficiency and continuous requirements of automotive die-casting production are met. In essence, this step, by quantifying efficiency targets, guides the optimized design of the clamping system, thereby improving overall production efficiency.

[0039] In some embodiments, such as Figure 2As shown, an implementation method for surface pretreatment in a method for improving the clamping efficiency of multi-process die-casting molds for automobiles is provided, which is applicable to the die-casting process for producing high-precision parts such as automobile engine cylinder heads.

[0040] Step S31: Select high-strength mold steel or high-hardness aluminum alloy as the base of the die-casting mold.

[0041] Understandably, in order to meet the needs of multiple processes in automobile die casting production, such as liquid injection molding, cooling and solidification, demolding and cleaning preparation, high-strength mold steel (such as H13 steel) or high-hardness aluminum alloy (such as 7075 aluminum alloy) are selected as mold base materials.

[0042] Furthermore, through material performance testing, it was confirmed that the tensile strength of the matrix reaches 800-1200MPa and the hardness reaches HRC45-52, to ensure the durability and stability of the mold under high temperature and high pressure environment.

[0043] Understandably, this material selection provides a solid foundation for subsequent multi-process clamping and meets the strength requirements of complex processes.

[0044] Step S32: A multi-slot positioning structure is formed by precision CNC machining, with a slot depth of 0.5-2.0mm and a slot width of 2.0-6.0mm, in order to balance strength and machining efficiency.

[0045] Specifically, a five-axis CNC milling machine is used to machine the mold base, designing and forming a multi-slot positioning structure, including a deep slot for the liquid injection process and a shallow slot for the demolding process. The slot depth is controlled between 0.5-2.0 mm, and the slot width is controlled between 2.0-6.0 mm to balance positioning accuracy and mold strength. Furthermore, the milling path is optimized through CNC programming to ensure that the surface roughness Ra of the slot wall is ≤0.8 μm, improving the adaptability of the positioning structure. Understandably, this multi-slot positioning structure supports rapid switching between multiple processes, reducing clamping and adjustment time.

[0046] Step S33: After high-pressure cleaning and rust prevention treatment, dry at 80-100℃ for 20-45 minutes to form the highly adaptable treated surface.

[0047] Specifically, after the multi-slot positioning structure is processed, a high-pressure water cleaning device (pressure 10-15MPa) is used to remove cutting residues and oil stains from the surface of the mold substrate. Then, an environmentally friendly rust inhibitor is sprayed to form a uniform rust-proof protective layer.

[0048] Furthermore, the mold substrate is placed in a temperature-controlled drying oven and dried at 80-100℃ for 20-45 minutes to ensure that the surface is dry and the rust inhibitor is cured, forming a wear-resistant and corrosion-resistant highly adaptable treated surface.

[0049] Understandably, this surface treatment enhances the mold's durability and provides a stable positioning basis for the subsequent assembly of the clamping functional structures.

[0050] In some embodiments, an implementation of a multi-slot positioning structure in a method for improving the clamping efficiency of multi-process die-casting molds for automobiles is provided, which is applicable to the die-casting process for producing high-precision parts such as automobile chassis structural components.

[0051] Specifically, the multi-slot positioning structure includes a deep slot for the liquid injection process and a shallow slot for the demolding process. The deep slots and shallow slots are arranged alternately. The depth of the deep slots is 1.0-2.0 mm, and the depth of the shallow slots is 0.5-1.0 mm, which supports rapid switching between processes.

[0052] Understandably, when machining multi-slot positioning structures, deep slots are designed to enhance the positioning strength of the mold base to meet the high-pressure requirements of the liquid injection molding process. The depth of the deep slots is controlled between 1.0-2.0 mm to ensure stability under the impact of liquid metal. Shallow slots are designed to facilitate rapid adjustment of positioning to meet the rapid release requirements of the demolding and removal process. The depth of the shallow slots is controlled between 0.5-1.0 mm. The deep and shallow slots are arranged in an alternating pattern and machined using CNC milling equipment to ensure uniform slot spacing and a positioning point deviation of less than 0.02 mm.

[0053] The staggered slot design optimizes the positioning path, reduces clamping and adjustment time, and supports rapid switching between liquid injection, cooling, demolding, and cleaning processes. This multi-slot positioning structure, through differentiated slot depth design, meets the positioning requirements of multiple processes and improves clamping efficiency.

[0054] In some embodiments, an implementation method for a multi-process integrated clamping scheme design in a method for improving the clamping efficiency of automotive die-casting molds is provided, which is applicable to the die-casting process for producing high-precision parts such as automotive wheel hubs.

[0055] Specifically, the first clamping module is designed with high-precision positioning and dynamic locking functions, with a locking force of 1200-2800N to meet the stability requirements of multiple processes.

[0056] To meet the stability requirements of multiple processes including liquid injection molding, cooling and solidification, demolding, and cleaning, a first clamping module was designed. This module integrates high-precision positioning to ensure accurate mold positioning in each process, and features a dynamic locking function to provide a locking force of 1200-2800N to adapt to the mechanical requirements of different processes. The geometry of the positioning elements was optimized using computer-aided design (CAD) software to ensure a positioning point deviation of less than 0.02mm, and the module is made of high-strength alloy material to enhance durability. Understandably, this module provides a stable foundation for multi-process clamping, supporting continuous operation of complex processes.

[0057] Furthermore, the first clamping module is fixed to the processing surface via a quick connection method to form a first clamping layer.

[0058] Based on the highly adaptable surface treatment, a quick-connect method (such as magnetic or snap-fit ​​mechanism) is used to fix the first clamping module to the mold base surface, forming the first clamping layer. The quick-connect method, through standardized interface design, ensures that module installation and removal time is less than 5 seconds, meeting the requirements for rapid switching between multiple processes. During installation, the module position is adjusted using precision calibration tools to ensure that the fitting accuracy with the multi-slot positioning structure on the mold base is within 0.01mm. Specifically, the quick-connect uses a high-precision snap-fit ​​mechanism (snap-fit ​​tolerance ±0.005mm), combined with a pneumatic push rod (thrust 500-1000N) to achieve rapid installation. Combined with the low-friction characteristics of the highly adaptable surface treatment (friction coefficient less than 0.1), the installation time is controlled within 3-5 seconds, improving switching efficiency. In summary, the formation of the first clamping layer enhances the stability and compatibility of the clamping system, providing a reliable foundation for subsequent module assembly.

[0059] Furthermore, a second clamping module is designed, integrating a dynamic adjustment mechanism, and assembled on the first clamping layer to form the efficient clamping functional structure.

[0060] Specifically, a second clamping module is designed, integrating a dynamic adjustment mechanism. This mechanism enables rapid switching between processes through adjustable positioning elements, such as flexibly adjusting between the high-pressure state of the injection process and the rapid release state of the demolding process. The second clamping module is made of lightweight, high-strength materials and assembled on the first clamping layer. Dynamic adjustment is achieved through a sliding or rotating mechanism, with adjustment time controlled within 3-6 seconds to ensure efficient process switching. The dynamic adjustment mechanism employs precision sliding guides (guide accuracy 0.01mm) and rotary joints (rotation resolution 0.1°), achieving rapid adjustment through pneumatic or hydraulic drive (drive pressure 0.3-0.5MPa). Combined with a real-time position feedback system (resolution 0.005mm), the adjustment time is ensured to be controlled within 3-6 seconds. In essence, this module, together with the first clamping layer, constitutes a highly efficient clamping functional structure, significantly improving multi-process clamping efficiency and adapting to the production of complex parts such as automotive wheel hubs.

[0061] In some embodiments, an implementation method for automated multi-process optimization in a method for improving the clamping efficiency of automotive die-casting molds is provided, which is applicable to the die-casting process for producing high-precision parts such as automotive suspension components.

[0062] Specifically, the clamping functional structure is placed in an automated process environment that supports multi-process clamping optimization, with an environment accuracy of 0.01-0.03mm and a switching speed of 20-40mm / s, to meet the requirements of high-precision mold processing.

[0063] The efficient clamping mechanism is placed within an automated process environment that supports multi-process optimization. This environment utilizes a high-precision CNC machining platform to ensure positioning accuracy is controlled within 0.01-0.03mm and switching speed is maintained at 20-40mm / s, meeting the high-precision requirements of processes such as liquid injection molding, cooling and solidification, demolding, and cleaning preparation. Environmental accuracy refers to the positioning control accuracy of the machining platform. High-precision linear motors (resolution 0.005mm) and a closed-loop servo system (feedback frequency 100Hz) maintain the stability of the platform's motion trajectory, ensuring a positioning error within the 0.01-0.03mm range. The switching speed is achieved at 20-40mm / s through optimized motor drive parameters (acceleration 2-5m / s²), meeting the requirements for efficient switching. Simultaneously, environmental calibration adjusts the platform's table flatness and motion trajectory to ensure the stability of the clamping mechanism during multi-process switching. In essence, this automated process environment provides precise process support for efficient clamping, adapting to the processing needs of complex molds.

[0064] Furthermore, by simulating multi-process switching through an automated program, the positioning elements are adjusted for 30-80 minutes to ensure that the switching error is less than 0.02mm.

[0065] Specifically, automated control software simulates the switching process of liquid injection, cooling, demolding, and cleaning. A preset program dynamically adjusts the positioning elements in the clamping functional structure, with the adjustment time controlled between 30 and 80 minutes. During the adjustment, the movement path and angle of the positioning elements are optimized to ensure that the positioning error during each process switch is less than 0.02 mm. The adjustment time range of 30-80 minutes depends on the mold complexity and the number of processes; simple molds (such as small suspension components) require 30-50 minutes, while complex molds (such as large suspension components) require 50-80 minutes. A high-precision stepper motor (0.01 mm step accuracy) drives the positioning elements, and a laser measurement system (0.005 mm resolution) monitors the position deviation in real time, iteratively optimizing the adjustment path to ensure a switching error of less than 0.02 mm. Through multiple simulation iterations, switching data is recorded and analyzed, and adjustment parameters are optimized to reduce errors. Understandably, this step improves the switching accuracy of the positioning elements through automated simulation, significantly shortening the process switchover time.

[0066] Furthermore, the die-casting mold for automobiles with improved clamping efficiency is obtained by curing and locking it at room temperature for 1.5-3 hours.

[0067] Specifically, after adjusting the positioning elements, the clamping functional structure is placed in a room temperature (20-25℃) environment for curing and locking for 1.5-3 hours to ensure the positional stability of the positioning elements. Then, by applying an appropriate fixing force (1000-1500N), the modular clamping structure is fixed to prevent minor displacements in subsequent processes. Understandably, this curing and locking process reinforces the optimized clamping functional structure, forming an automotive die-casting mold that improves clamping efficiency and is suitable for efficient and continuous automotive die-casting production.

[0068] In some embodiments, an implementation method for applying a high-temperature resistant and anti-corrosion coating in a method for improving the multi-process clamping efficiency of automotive die-casting molds is provided, which is applicable to the die-casting process for producing high-precision parts such as automotive engine cylinder blocks.

[0069] Specifically, a high-temperature resistant and corrosion-resistant coating with a thickness of 10-30 μm is applied to the surface of the clamping functional structure to improve its durability under high temperature and high pressure environments.

[0070] Understandably, after completing the automated multi-process optimization of the clamping functional structure, a high-temperature resistant and corrosion-resistant coating is applied to the surface of the clamping functional structure using plasma spraying technology. Ceramic-based coating materials (such as alumina-titanium oxide composite coating) are selected, and the coating thickness is controlled to be 10-30μm to withstand the high temperature environment of up to 600-700℃ and high pressure impact during the liquid injection molding process.

[0071] By precisely controlling the spraying speed and spray gun distance, coating uniformity is ensured, with a surface roughness Ra≤1.6μm, improving coating adhesion and corrosion resistance. This coating significantly enhances the durability of the clamping structure under high temperature and high pressure environments, reduces wear during multi-process operation, and extends mold life.

[0072] In some embodiments, an implementation method for clamping efficiency testing and quality certification in a multi-process clamping efficiency improvement method for automotive die-casting molds is provided, which is applicable to the die-casting process for producing high-precision parts such as automotive gearbox housings.

[0073] Specifically, a multi-process clamping efficiency test was conducted, covering four processes: liquid injection, cooling, demolding, and cleaning. The test time was 15-60 minutes, which was used to verify the achievement of the clamping efficiency improvement target.

[0074] Understandably, after applying the high-temperature resistant and corrosion-resistant coating, a multi-process clamping efficiency test was conducted on the clamping functional structure, covering four processes: liquid injection molding, cooling and curing, demolding and removal, and cleaning and preparation. The test was conducted in a simulated production line environment, with the test time controlled between 15 and 60 minutes. By recording the switching time and positioning stability data of each process, the clamping efficiency improvement target was verified.

[0075] Timing equipment and optical measurement systems were used to monitor the process changeover to ensure that the test data accurately reflected the clamping performance. This test, simulating actual production, confirmed the efficiency and stability of the clamping system during multi-process operation.

[0076] Furthermore, when the clamping and switching time is reduced by more than 45%, the automotive die-casting mold is subjected to quality certification.

[0077] Specifically, test data is analyzed to calculate the reduction in changeover time for multi-process clamping compared to traditional methods. When the total changeover time is reduced by more than 45%, the clamping efficiency improvement target is confirmed to have been achieved. Automotive die-casting molds are certified through a quality management system (such as ISO 9001) to verify their performance stability during injection, cooling, demolding, and cleaning processes, including the mold's positioning accuracy and durability.

[0078] Understandably, this quality certification ensures that the molds meet the requirements of efficient automotive die-casting production, enhancing the reliability of the production line and market competitiveness.

[0079] In some embodiments, an implementation method for designing the clamping layer thickness in a multi-process clamping efficiency improvement method for automotive die-casting molds is provided, which is applicable to the die-casting process for producing high-precision parts such as automotive body structural components.

[0080] Specifically, the thickness of the first clamping layer is 15-50mm, and the thickness of the second clamping layer is 8-30mm. The thickness of the first clamping layer is greater than that of the second clamping layer to ensure the stability of clamping in multiple processes.

[0081] Understandably, when designing a multi-process integrated clamping scheme, the thickness of the first clamping layer is determined to be 15-50mm to provide sufficient structural strength to support the high-pressure impact of the injection molding process and the thermal stress of the cooling and curing process; the thickness of the second clamping layer is designed to be 8-30mm to ensure flexibility to support the rapid switching of demolding and cleaning preparation processes, while keeping the thickness of the first clamping layer greater than that of the second clamping layer to enhance overall stability.

[0082] Furthermore, by finite element analysis to simulate the stress distribution of the clamping layer in multiple processes, the thickness selection was optimized to ensure the positioning stability and durability of the mold during continuous operation. This thickness design, through differentiated allocation, balances the stability and switching efficiency of multi-process clamping, adapting to the needs of high-precision die-casting production.

[0083] In some embodiments, an implementation method for dynamic adjustment mechanism and efficiency verification in a multi-process clamping efficiency improvement method for automotive die casting molds is provided, which is applicable to the die casting process for producing high-precision parts such as automotive gearbox housings.

[0084] Specifically, the multi-process integrated clamping scheme achieves seamless connection between liquid injection, cooling, demolding, and cleaning processes through a dynamic adjustment mechanism, and the clamping efficiency improvement parameter satisfies the following formula: Where E represents the clamping efficiency improvement parameter, This represents the clamping force weighting coefficient. This represents the switching time weighting coefficient. This represents the positioning accuracy weighting coefficient. Indicates the clamping force distribution. Indicates process changeover time. Indicates positioning accuracy (unit: mm). , The values ​​of γ and γ are determined by the process requirements and the characteristics of the mold material, and their typical values ​​are 0.4-0.6, 0.2-0.4, and 0.1-0.3, respectively.

[0085] Understandably, to achieve seamless integration of injection, cooling, demolding, and cleaning processes, the multi-process integrated clamping solution employs a dynamic adjustment mechanism. This mechanism adapts to the different requirements of each process by adjusting the positioning elements within the clamping structure, such as the high-pressure stability required for injection and rapid release during demolding. The clamping efficiency improvement parameter E is determined by comprehensively considering the clamping force distribution (…). Process changeover time and positioning accuracy An evaluation is conducted. For example, during the production of the gearbox housing, a dynamic adjustment mechanism ensures... Within the range of 1200-2800N, Less than 8 seconds Less than 0.02mm. Weighting coefficients α (0.4-0.6), β (0.2-0.4), and γ (0.1-0.3) are determined based on process simulation and mold material characteristics. For the injection process, clamping force is prioritized; for the demolding process, switching time is prioritized. The understandable dynamic adjustment mechanism achieves rapid switching through precision sliding guides (guide accuracy 0.01mm) and rotary joints (rotation resolution 0.1°), coupled with closed-loop feedback control (feedback frequency 50Hz) to ensure… Less than 8 seconds Less than 0.02 mm; optimized through finite element analysis. Distribution ensures the stability of the liquid injection process. Subsequently, through multiple iterative tests in a simulated production environment, the adjustment parameters of the dynamic adjustment mechanism are optimized to maximize the E-value and achieve seamless integration between processes. Understandably, this step significantly improves clamping efficiency by dynamically balancing clamping force, switching time, and positioning accuracy, meeting the demands of high-precision automotive die-casting production.

[0086] Furthermore, the typical value ranges of the weighting coefficients α, β, and γ (0.4-0.6, 0.2-0.4, 0.1-0.3) were determined through process requirement analysis and mold material characteristic testing. In the injection process, clamping force contributes 40-60% to efficiency, hence the higher α value; in the demolding and cooling processes, changeover time accounts for 20-40%, followed by the β value; in the cleaning process, positioning accuracy accounts for 10-30%, resulting in a lower γ value. Further, for high-strength mold steels (such as H13 steel, with a tensile strength of 800-1200 MPa), the injection process requires a larger clamping force, supporting a higher α value; high-hardness aluminum alloys (such as 7075 aluminum alloy) are more suitable for rapid changeover, making the β value relatively important. The weighting coefficients were optimized to balance efficiency through process simulation and production line testing. Understandably, these typical values ​​ensure that the dynamic adjustment mechanism adapts to different processes and materials, improving clamping efficiency.

[0087] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A method for improving the multi-process clamping efficiency of automotive die-casting molds, characterized in that, The method includes the following steps: analyzing the multi-process machining requirements of automotive die-casting molds, identifying the clamping requirements for the injection molding, cooling and solidification, demolding and removal, and cleaning preparation processes; for the injection molding process, determining the clamping force requirement range to be 2500-4500N to meet the high-pressure requirements of aluminum alloy die casting; for the cooling and solidification and demolding processes, setting the process switching time to be less than 8 seconds to meet the high-efficiency production rhythm; for the cleaning preparation process, determining the positioning accuracy requirement to be less than 0.015mm to ensure the machining quality of complex molds; based on the above requirements, setting... The target for improving multi-process clamping efficiency is to reduce the total changeover time by 35-55%. The die-casting mold substrate undergoes surface pretreatment, and a multi-process compatible positioning structure is machined to form a highly adaptable surface. High-strength mold steel or high-hardness aluminum alloy is selected as the die-casting mold substrate. A multi-slot positioning structure is formed through precision CNC machining, with a slot depth of 0.5-2.0 mm and a slot width of 2.0-6.0 mm to balance strength and machining efficiency. After high-pressure cleaning and rust prevention treatment, it is dried at 80-100℃ for 20-45 minutes to form the highly adaptable surface. The process involves: surface preparation; designing a multi-process integrated clamping scheme, forming an efficient clamping functional structure through modular assembly; designing a first clamping module with high-precision positioning and dynamic locking functions, with a locking force of 1200-2800N to meet the stability requirements of multiple processes; fixing the first clamping module to the processed surface via a quick connection method to form a first clamping layer; designing a second clamping module with an integrated dynamic adjustment mechanism, assembling it on the first clamping layer to form the efficient clamping functional structure; performing automated multi-process optimization of the clamping functional structure in an automated process environment, enabling rapid switching of positioning elements between processes to obtain an automotive die-casting mold with improved clamping efficiency; placing the clamping functional structure in an automated process environment supporting multi-process clamping optimization, with an environmental accuracy of 0.01-0.03mm and a switching speed of 20-40mm / s to meet the high-precision mold processing requirements; simulating multi-process switching through an automated program, adjusting the positioning elements for 30-80 minutes to ensure a switching error of less than 0.02mm; and curing and locking at room temperature for 1.5-3 hours to obtain the automotive die-casting mold with improved clamping efficiency.

2. The method for improving the multi-process clamping efficiency of automotive die-casting molds as described in claim 1, characterized in that, The multi-slot positioning structure includes a deep slot for the liquid injection process and a shallow slot for the demolding process. The depth of the deep slot is 1.0-2.0 mm, and the depth of the shallow slot is 0.5-1.0 mm, supporting rapid switching between processes.

3. The method for improving the multi-process clamping efficiency of automotive die-casting molds as described in claim 1, characterized in that, The step of optimizing the clamping functional structure through automated multi-process processes further includes: applying a high-temperature resistant and corrosion-resistant coating to the surface of the clamping functional structure, with a coating thickness of 10-30μm, to improve its durability under high temperature and high pressure environments.

4. The method for improving the multi-process clamping efficiency of automotive die-casting molds as described in claim 3, characterized in that, The steps following the application of the high-temperature resistant and anti-corrosion coating also include: conducting a multi-process clamping efficiency test, covering four processes: liquid injection, cooling, demolding, and cleaning, with a test time of 15-60 minutes, to verify the achievement of the clamping efficiency improvement target; when the clamping changeover time is reduced by more than 45%, the automotive die-casting mold is quality certified.

5. The method for improving the multi-process clamping efficiency of automotive die-casting molds as described in any one of claims 1-4, characterized in that, The thickness of the first clamping layer is 15-50mm, and the thickness of the second clamping layer is 8-30mm. The thickness of the first clamping layer is greater than that of the second clamping layer to ensure the stability of clamping in multiple processes.

6. The method for improving the multi-process clamping efficiency of automotive die-casting molds as described in any one of claims 1-4, characterized in that, The multi-process integrated clamping scheme achieves seamless connection between liquid injection, cooling, demolding and cleaning processes through a dynamic adjustment mechanism. The clamping efficiency improvement parameter satisfies the following formula: Where E represents the clamping efficiency improvement parameter, This represents the clamping force weighting coefficient. γ represents the switching time weighting coefficient, and γ represents the positioning accuracy weighting coefficient. Indicates the clamping force distribution. Indicates process changeover time. Indicates positioning accuracy. β and γ are determined by the process requirements and the properties of the mold material.

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